Compact gasifier-genset architecture

ABSTRACT

A compact biomass gasification-based power generation system that converts carbonaceous material into electrical power, including an enclosure that encases: a gasifier including a pyrolysis module coaxially arranged above a reactor module, a generator including an engine and an alternator, and a hopper. The generator system additionally includes a first heat exchanger fluidly connected to an outlet of the reactor module and thermally connected to the drying module, a second heat exchanger fluidly connected to an outlet of the engine and thermally connected to the pyrolysis module, and a third heat exchanger fluidly connected between the outlet of the reactor module and the first heat exchanger, the third heat exchanger thermally connected to an air inlet of the reactor module. The system can additionally include a central wiring conduit electrically connected to the pyrolysis module, reactor module, and engine, and a control panel connected to the conduit that enables single-side operation.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/509,753 filed 12 Jul. 2019, which is a continuation of U.S. patentapplication Ser. No. 15/687,256 filed 25 Aug. 2017, which is acontinuation of U.S. patent application Ser. No. 15/281,459, which is acontinuation of U.S. patent application Ser. No. 14/452,325 filed 5 Aug.2014, which is a continuation of U.S. patent application Ser. No.13/833,918 filed 15 Mar. 2013, which claims benefit to U.S. ProvisionalNo. 61/617,658 filed 29 Mar. 2012, all of which are incorporated intheir entirety by this reference.

This application is related to U.S. patent application Ser. No.12/846,807, filed 29 Jul. 2010 and titled “SYSTEM AND METHOD FORDOWNDRAFT GASIFICATION,” which is incorporated in its entirety by thisreference.

TECHNICAL FIELD

This invention relates generally to the power generation field, and morespecifically to an improved biomass gasification based power generatorin the power generation field.

BACKGROUND

Biomass gasification based generators are an attractive method for powergeneration, given they are fueled with carbonaceous byproducts that areinexpensive or free to source. However, conventional biomass gasifiersare often large, sprawling assemblies, preventing consumer adoption dueto their significant footprint, complexity of operation, and difficulttransport logistics. What is desired is a complete and compact biomasspower generation system in a single box enclosure, in the manner typicalof a liquid-fueled genset, such as a diesel or LPG generator. However,it is difficult to achieve this configuration with a gasifier gensetgiven the significant number of components involved, the large hopperrequired for low energy density biomass, and the complexity of solidfuel feeding systems. Until these problems are solved, very few biomassgasification based generators will be deployed, and their many potentialbenefits will not be realized. Therefore, there is a need in the biomassgasification generator field to create an improved, fully integrated,and compact system that meets user expectations for contemporary powergeneration equipment.

BRIEF DESCRIPTION OF THE FIGURES

FIGS. 1A and 1B are a side and top view of a variation of the powergeneration system, respectively.

FIGS. 2A and 2B are a side and top view of a specific example of thepower generation system, respectively.

FIGS. 3A and 3B are a side and top view of an example of the powergenerator system with a swirl hopper material transporter.

FIGS. 4A and 4B are a side and top view of a second variation of thepower generation system, respectively.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description of the preferred embodiments of the inventionis not intended to limit the invention to these preferred embodiments,but rather to enable any person skilled in the art to make and use thisinvention.

1. Gasifier-Engine Generator System

As shown in FIG. 1, the improved power generation system 10 includes askid 110, a hopper 200, a drying module 400, a gasifier 500 including apyrolysis module 510 and a reactor module 550, a particulate separator600, a filtration module 700, and an engine module 800 that cooperate toproduce gaseous fuel (syngas or producer gas) from carbonaceousmaterial, and to extract particulates from the gaseous fuel. Thegasifier 500 is preferably a downdraft gasifier, but can be any othersuitable gasifier. This power generation system 10 is preferablyarranged to leverage gravity in transferring fuel precursors todifferent processing modules, and to leverage various waste heat streamsto improve gasifier performance. Furthermore, the arrangement allows thepower generation system 10 to have a substantially small footprint(preferably rectangular, more preferably square), such that it can fiton a shipping pallet or within a shipping container. This arrangementalso preferably shortens the piping connections between differentmodules, and allows for control valves to be localized in one area, morepreferably on one side of the power generation system 10, for ease ofuser operation. In one variation of the power generation system 10, theelectronics (e.g., engine module), filters, and engine-flare valves(e.g., valves that switch fuel flow between the flare to the engine) arearranged along a common edge of the base 10 to simplify user operation.This arrangement can also allow the power generation system 10 to beshipped in a substantially ready-to-use arrangement, with little to noadditional assembly required by the consumer.

The skid 110 of the power generation system 10 functions to support thecomponents of the power generation system 10. The skid 110 is preferablya portion of an enclosure 100, which functions to mechanically protectthe components of the power generation system 10. However, the powergeneration system 10 can alternatively only include the skid 110, andnot include walls or a top. The enclosure 100 can additionally functionto trap and direct the radiator blast upwards toward and potentiallythrough the hopper 200. The enclosure 100 preferably includes wallsextending perpendicularly from the skid 110. The enclosure 100 canadditionally include a top 130 arranged parallel the skid 110 across thewalls 120. The skid 110 is preferably rectangular or square, with afirst corner adjacent a second corner, a third corner adjacent thesecond corner, and a fourth corner adjacent the first and third corners,but can have any suitable geometric shape. The skid 110 preferablydefines the power generation system footprint, but the system footprintcan be otherwise defined. In one variation, the skid 110 is a pallethaving standardized dimensions, more preferably standardized shippingpallet dimensions. The enclosure 100 preferably includes four walls,each extending from a respective skid edge, but can alternativelyinclude any suitable number of walls, preferably one wall for each edge.The skid 110 and top can be substantially solid, be porous, be solidwith a porous segment, be made of a plurality of tubes or planks, orhave any other suitable construction or configuration. The walls 120 arepreferably substantially solid, but can alternatively be porous, made ofmultiple tubes or planks, or have any other suitable construction. Thetop and walls are preferably removable from the base, but canalternatively be substantially permanently coupled to the base (e.g.,welded to the base). The top and walls can alternatively articulaterelative to the base (e.g., be coupled by hinges to the base). Theenclosure 100 can be a standardized shipping container (e.g., astandardized 20-ft intermodal container, 40-ft high-cube intermodalcontainer, or any other suitable shipping container, etc.), a containerbuilt around a standardized base (e.g., a standardized 48 in×48 inpallet or any other suitable standardized pallet), or a container havingany other suitable dimensions. The enclosure 100 is preferably metal(e.g., steel, a corrosion-resistant metal, or any other suitable metal),but can alternatively be made of wood, plastic, or any other suitablematerial. The enclosure 100 is preferably substantially rigid andopaque, but can alternatively be clear. The enclosure 100 is preferablymade from an extruded metal sheet, bent and welded into a cube, but canbe otherwise manufactured. The enclosure 100 is preferably encases thedrying module 400, the gasifier 500 including the pyrolysis module 510and the reactor module 550, and the particulate separator 600. Theenclosure 100 can additionally enclose the airlock 300 if an airlock isused. The enclosure 100 can additionally enclose the engine module 800,the filtration module 700, and the control system. The enclosure 100 ispreferably allows free air flow between the ambient environment and theenclosure interior, but can alternatively hold an air seal. Theenclosure 100 can additionally enclose the hopper 200, but the hopper200 can alternatively be mounted to enclosure 100 prior to generatoruse, wherein the hopper 200 is preferably mounted to the end of thewalls 120 distal the skid 110 (e.g., by nuts and bolts coupling a flangeof the hopper to the enclosure 100) but can alternatively be mounted toany suitable portion of the enclosure 100. The enclosure 100 can enclosea collapsed hopper, an extended hopper, a rigid hopper, cooperativelydefine the hopper with one or more auxiliary walls, or enclose any othersuitable hopper.

The carbonaceous material fed into the power generation system 10 can beany suitable material that contains carbon, for example, biomass (e.g.,wood, plants, algae), biodegradable waste (e.g., any waste generated bya plant or animal), or coal. The carbonaceous material is preferably fedinto the hopper 200 by the user, but can alternatively be fed into thehopper 200 by a mechanized system or in any other suitable manner. Inthe power generator system 10, the carbonaceous material is converted toengine-grade gaseous fuel. The carbonaceous material is first dried bythe drying module 400 and pyrolyzed into tar gas and charcoal in thepyrolysis module 510. The tar gas is then combusted and reduced withinthe reactor module 550 to create gaseous fuel, which is then passedthrough the air preheating- and gas cooling-heat exchanger 560, exitsinto the particulate separator 600 for particulate separation, is fedinto the walls of the drying module 400 to dry the incoming carbonaceousmaterial, is filtered in the filtration module 700, and is then fed intothe carburetor of the engine module 800.

The power generator system 10 recaptures waste heat from both thegasifier and engine outputs, thereby simultaneously improving gasifierperformance and reducing component count by cooling the gasifier outputwithout a dedicated cooling module. In particular, the hot, gaseous fuelproduced by the reactor module 550 preheats the air used for combustionwithin the reactor module 550 and also dries and preheats thecarbonaceous fuel in the drying module 400; the hot exhaust gas from theengine 810 is used to heat the pyrolysis module 510; and the radiatorblast from the engine module 800 is used for the first stage of dryingthe carbonaceous material in the hopper 200.

The hopper 200 of the power generation system 10 functions to receivecarbonaceous material and can function to facilitate moisture removalfrom the carbonaceous material. The hopper 200 is preferably open to theambient environment, but can alternatively be sealed, or have theability to hold an air seal. In a first variation of the hopper 200, thehopper 200 preferably includes a carbonaceous material inlet that allowscarbonaceous material to enter the hopper 200 and a hopper boot thatallows carbonaceous material to egress into the drying module 400. Thecarbonaceous material inlet is preferably the open top of the hopper200, but can alternatively be a channel, pipe, flume any other suitablelead-in in the side or base of the hopper 200. The hopper boot ispreferably a controlled opening on the bottom of the hopper 200, and ispreferably located above the drying module inlet, more preferablysubstantially near the center of the hopper base 210, but alternativelyin any suitable position. The hopper 200 is preferably a generallycylindrical structure, and preferably has a diameter substantiallysimilar to the width of the skid (shipping pallet) or enclosurefootprint, but can alternatively be conical or any other suitable shape.An end of the hopper 200 is preferably fastened to the inlet of thedrying module 400 (e.g., with nuts and bolts or any other suitablefastener), such that the hopper 200 is coupled to the drying module 400during shipping or transportation, but the hopper 200 can alternativelybe removably coupled to the drying module 400, be a separate componentthat is shipped in the same enclosure, or can be a component that theuser assembles and installs. The hopper 200 is preferably made of aflexible material, preferably supported by ribbing (e.g., rings or aspiral along the height of the hopper 200), such that it can collapseand be transported with the body of the power generation system 10.Alternatively, the hopper 200 can be formed from multiple pieces ofhinged material that can collapse into a substantially flatconfiguration for shipping, but can be extended to form a substantiallycylindrical hopper 200. Alternatively, the hopper can be made of solidmaterial, without collapsible features, and be shipped in its fullydistended and operational form. The hopper material is preferably porousto allow better carbonaceous material drying, wherein the pores arepreferably smaller than the carbonaceous material particulate size. Inone variation, the hopper 200 includes a perforated base thatfacilitates carbonaceous material pre-drying with radiator heat from theengine 810 or particulate separator 600. The hopper material ispreferably polymeric and corrosion-resistant, but can alternatively betreated, coated, or be bare metal. The hopper 200 is preferably formedfrom an extruded piece of material, but can alternately be formed fromone or more pieces of woven, injection molded, cast, sintered, or anyother suitable material manufactured in any suitable manner. The hopper200 is preferably substantially transparent such that the user can seethe fuel level, but can be semi-transparent or substantially opaque.However, any other suitable hopper in any suitable configuration thatreceives carbonaceous material can be utilized. In a second variation ofthe hopper, the hopper 200 is preferably substantially defined by thewalls of the enclosure 100. More preferably, the hopper 200 occupies andis at least partially defined by an end of the enclosure 100 (e.g., thehopper 200 extends along approximately half of the enclosurelongitudinal axis). The hopper 200 preferably includes a flat bottom,but can alternatively include an angled bottom, wherein the lowerportion is preferably adjacent the enclosure end, or have any othersuitable geometry. The hopper base 210 is preferably louvered orperforated to promote carbonaceous material drying, but canalternatively be solid. In one alternative of the hopper 200, the engineradiator 820 or particulate separator 600 extends under the raisedportion of the angled hopper base 210. The hopper 200 can additionallyinclude an external material transporter that moves carbonaceousmaterial from the enclosure exterior to the hopper interior. Theexternal material transporter preferably moves carbonaceous materialfrom an area proximal the skid 110 to the top of the hopper 200, but canalternatively move carbonaceous material to and from any suitableposition.

The hopper 200 can additionally include a carbonaceous materialtransporter 220 that moves the carbonaceous material from the body ofthe hopper 200 to the drying module 400, preferably through the airlock300 but alternatively through an opening in the bottom of the hopper200. The carbonaceous material transporter 220 preferably removes thecarbonaceous material from the bottom of the hopper (e.g., the portionof the hopper proximal the drying module 400 but alternatively theportion of the hopper 200 proximal the skid 110), but can alternativelyremove any suitable portion of the carbonaceous material within thehopper 200. The carbonaceous material transporter 220 is preferablysubstantially parallel to the hopper base 210, but can alternatively beat an angle to the hopper base 210. The carbonaceous materialtransporter 220 is preferably a full bottom feeder, such as a sweepauger, scroll feeder, vibratory feeder, rotary table feeder, chainfeeder, or any suitable material transporter. Utilizing a full bottomfeeder can confer several benefits: first, it allows for a substantiallycylindrical hopper to be used instead of a tapered hopper, which suffersfrom low hopper volume, failures with large and/or inconsistent fuels,and the bridging and arching modes of taper feeders. Second, a fullbottom feeder allows for a low and wide hopper to be used, which allowsfor easier transportation and use (e.g., the hopper 200 is easier tofill). The full bottom feeder can include a sweep auger, scroll feeder,a rotary feed table, rotary plow feeder, vibratory feeder, flat bottomfeeder, any suitable transporter that feeds solid fuel from a flatbottom container to single outlet chute. The rotation speed of thecarbonaceous material transporter 220 can be varied depending on thefuel requirement of the gasifier 500 the existing carbonaceous materialcontent within the gasifier 500, and/or any other suitable factor. Thecarbonaceous material transporter 220 can be hand driven, but canalternatively be coupled to a motor that automatically rotates the augerto regulate the carbonaceous material within the gasifier 500. However,any other suitable type of transporter can be used for the carbonaceousmaterial. Alternatively, gravity can be used to feed carbonaceousmaterial to the drying module 400, particularly when the hopper geometryfacilitates (e.g., funnels) carbonaceous material transportation. Thisvariation can decrease the need for a driven material transporter, andcan decrease the amount of energy required to run the gasifier 500. Thecarbonaceous material within the hopper 200 is preferably pre-heated andpartially dried by the hot air from the radiator blast of the engine810, but can alternatively be pre-heated and dried from heat radiatingfrom the drying module 400, heat radiating from the body of the gasifier500, or simply dried by allowing the moisture in the carbonaceousmaterial to equilibrate with the ambient environment. The carbonaceousmaterial in the hopper 200 can additionally be pre-heated/dried from anyother heat source. In one variation, the carbonaceous materialtransporter 220 is angled relative to the skid no (e.g., relative to anormal vector or broad face of the skid no). This can be particularlydesirable when the hopper base 210 is angled, wherein the angle of thecarbonaceous material transporter 220 is preferably substantially thesame as the hopper base 210 angle. The carbonaceous material transporter220 preferably includes first end and a second end, wherein the firstend is preferably lower than the second end.

The power generation system 10 can additionally include airlock 300 thatfunctions as an airlock transition point that seals the gasifier 500,preventing gas (air) ingress or egress, while maintaining the flow ofmaterial between the hopper 200 and the drying module 400. However, somevariations of the power generation system 10 an exclude an airlock,wherein the hopper preferably maintains an air seal for the remainder ofthe power generation system 10. Effectively, the airlock 300 maintainsan air seal in the body of the gasifier 500, more preferably with theinlet of the drying module 400, such that airflow within the body of thegasifier 500 can be controlled, which is desirable because pyrolysis inthe pyrolysis module 510 must occur in the absence of oxygen and becauseachieving a strong air blast out the nozzles in the reaction modulerequires pulling or pushing against a sealed reactor environment.Furthermore, the airlock 300 feeds carbonaceous material from theambient environment into the sealed system. The airlock 300 ispreferably arranged within the hopper boot (e.g., hopper base 210), butcan alternatively be arranged between the hopper boot and the dryingmodule 400, within the hopper 200 before the hopper boot, or within thedrying module 400. Alternatively, the airlock 300 can be located below araised end of the carbonaceous material transporter, such as when thecarbonaceous material transporter is angled relative to the skid 110.The airlock 300 arrangement allows for the body of the gasifier 500 tohold an air seal while allowing the hopper 200 to be open to the ambientatmosphere. This airlock configuration confers two benefits: first,airflow within the body of the gasifier 500 can be controlled. Second,the airlock placement allows the hopper 200 to be open to the ambientenvironment. This permits the hopper 200 to be collapsible, allowing foreasy transportation (e.g., during shipping); eliminates the need forairtight installation of a new hopper, allowing the hopper volume to beeasily changed; and allows for the carbonaceous material pre-drying (inthe hopper 200) to the ambient environment, which removes moisture fromthe system such that moisture introduction into the reactor module isreduced, thereby preventing thermal drag on reactor temperatures. Theairlock 300 is preferably a rotary airlock feeder, but can alternativelybe a single or double sluice value, a double dump mechanism, an irisvalve, a rotating plate valve, or any suitable airlock 300. The rotaryairlock feeder is preferably oriented with the rotational axisperpendicular to a gravity vector, but can alternatively be orientedwith the rotational axis parallel to the gravity vector, or oriented inany suitable position. The carbonaceous material transport mechanismpreferably feeds carbonaceous material to the airlock 300, but theweight of the carbonaceous material can also feed the carbonaceousmaterial to the airlock 300.

The drying module 400 of the power generation system 10 functions tohold and dry a quantity of the carbonaceous material. The drying module400 is preferably located within the air-sealed environment of thegasifier 500, and preferably includes a portion arranged substantiallybelow the hopper 200, more preferably below the airlock 300, such thatundried carbonaceous material is dropped into the drying module 400.However, the drying module 400 can be arranged beside the hopper 200 orin any other suitable position. The drying module 400 preferablyincludes a carbonaceous material inlet in communication with the hopper200 that allows carbonaceous material into the drying module 400, and acarbonaceous material outlet that allows carbonaceous material out ofthe drying module 400 and into the pyrolysis module 510. Carbonaceousmaterial is preferably transported through the airlock 300 from thehopper 200, through the carbonaceous material inlet, and into the dryingmodule 400, wherein the carbonaceous material is preferably heated anddried by the gaseous output of the reactor module 550. However,carbonaceous material can be transported through an open hole in thehopper bottom into the drying module 400. As the carbonaceous materialis heated, the water content of the carbonaceous material is vaporized.The water vapor will still pass through the reactor, but withsubstantially less thermal drag, given the energy intensive vaporizationstage is not reliant on heat from combustion in the gasifier. The dryingmodule 400 is preferably a traditional auger boot, with two angled wallsand two vertical walls, or a cylindrical vessel, but can be of anysuitable geometry. The drying module 400 preferably fastens to thehopper 200 or airlock 300 through endplates (e.g., by nuts and bolts,screws, or any other suitable fastening mechanism), but can otherwisefasten to the hopper 200 or airlock 300.

In one variation, the drying module 400 is a straight channel entirelylocated below the hopper 200, oriented with a longitudinal axis parallelthe longitudinal axis of the hopper 200. The drying module 400 ispreferably substantially smaller than the hopper 200, and is preferablylocated near the center of the hopper 200 but can alternatively beeccentrically arranged relative to the hopper center. The inlet ispreferably the top of the drying module 400 (the part proximal thehopper 200), and the outlet is preferably arranged on the side of thedrying module 400 near the bottom of the drying module 400 (the partdistal the hopper 200). The bulk of the drying module 400 is preferablyoffset from and arranged above the pyrolysis module 510 (e.g., distalthe skid 110), such that only the substantially dried carbonaceousmaterial is pulled from the bottom of the drying module 400 andtransported into the pyrolysis module 510. Because water vapor flowsupward and the wettest carbonaceous material is fed in from the top, thecarbonaceous material at the bottom of the drying module 400 is thedriest material, and the material that is most fit to undergo pyrolysis.In another variation, the drying module 400 includes a channel extendingat an angle from the hopper 200 to the pyrolysis module 510, wherein theinlet is preferably is arranged below the hopper 200 (or airlock 300)and the outlet is preferably connected to the top of the pyrolysismodule 510, distal the reactor module 550. However, the inlet and outletof the drying module 400 can be otherwise arranged.

The drying module 400 can additionally include a first heat exchanger420 thermally coupled to the drying module 400. The first heat exchanger420 preferably includes an inner jacket that is formed by rolling acontinuous piece of sheet metal and preferably includes flange ringscoupled to the ends of the cylinder formed by the sheet metal and endplates fastened (e.g., using nuts and bolts or any other suitablefastener) to the sheet metal and flange rings that substantiallymaintains the rolled shape of the sheet metal. The drying module 400 canbe defined within the lumen of the inner jacket, or can be a separatecomponent located within the lumen defined by the inner jacket. Thefirst heat exchanger 420 preferably also includes an outer jacket,formed using substantially similar materials and methods as the innerjacket, that couples around the inner jacket through the endplates(e.g., by nuts and bolts, a weld, or any other suitable fasteningmechanism). Gaseous fuel from the reactor module 550 is preferablyintroduced into the first heat exchanger 420 to dry the carbonaceousmaterial, but gaseous fuel from the particulate separator 600 or gaseousfuel from the third heat exchanger 560 can alternatively be used. Thegaseous fuel path preferably extends from the particulate separator 600or the reactor module 550 up to the first heat exchanger 420. The inletof the first heat exchanger 420 is preferably arranged proximal theoutlet of the drying module 400, but can alternatively be proximal theinlet of the drying module 400. The outlet of the first heat exchanger420 is preferably fluidly connected to the filtration module 700 or tothe fuel inlet of the engine 810. The temperature of the gaseous fuelthat exits directly from the reduction reaction in typical gasifers canbe around 700-900° C., but the particulate separator 600 and/or thethird heat exchanger 560, which preheats the incoming air, can lower thetemperature of this gaseous fuel output to around 200° C.-300° C. Morepreferably, the gaseous fuel output temperature is preferably lowered toa range of around 150° C.-220° C. before ingressing into the first heatexchanger 420, such that maximal drying can be achieved without inducingpyrolysis. Preventing pyrolysis in the drying section can be desirableto avoid the build up of tar condensates and generally maintain thecleanliness of the system. However, any other suitable temperature canbe used.

To facilitate transport of the carbonaceous material into the pyrolysismodule 510, the drying module 400 can additionally include a secondcarbonaceous material transporter 440 that transports the driedcarbonaceous material from the drying module 400 into the pyrolysismodule 510. The material transporter is preferably an auger, but canalso be a drag chain, conveyor, plug feeder, walking floor or any othertype of transporter. The second carbonaceous material transporter 440preferably pulls carbonaceous material from the bottom of the dryingmodule 400, through the carbonaceous material outlet of the dryingmodule 400, and drops the dry carbonaceous material into the pyrolysismodule 510. Alternatively, the second carbonaceous material transporter440 can function as a lift, transporting the carbonaceous materialthrough the drying module 400 from a lower drying module inlet to ahigher drying module outlet. The second carbonaceous materialtransporter 440 is preferably substantially similar to the first, andpreferably operates at substantially the same speed, such thatcarbonaceous material flow through the system is substantially constant.However, the second carbonaceous material transporter 440 can be asubstantially different mechanism, run at a substantially differentspeed, and/or operated by a substantially different method.

The gasifier 500 of the power generation system 10 functions to producegaseous fuel from the carbonaceous material. The gasifier 500 ispreferably substantially fluidly sealed, aside from the air input of thereactor module 550, and is preferably capable of maintaining an internalpressure higher or lower than that of the ambient environment. Thegasifier 500 is preferably fluidly connected to the fuel input of theengine module 800, wherein the engine module 800 converts the gaseousfuel into rotary motion, then to electrical power. The gasifier 500preferably includes the pyrolysis module 510 and the reactor module 550.The gasifier 500 preferably additionally includes a second and thirdheat exchanger 560 that uses waste heat from the generated gaseous fueland the engine exhaust to heat the air heat exchanger 560, drying module400, and pyrolysis module 510, respectively. The gasifier 500 canadditionally include any other suitable generator component.

The pyrolysis module 510 of the gasifier 500 functions to pyrolyze drycarbonaceous material into tar gas and charcoal. More specifically, thecarbonaceous material is heated at a substantially high temperature(typically above 220° C.), in the substantial absence of oxygen, thusdistilling the carbonaceous material into tar gas and charcoal. Tar gasand charcoal are the precursors necessary for the following combustionand reduction stages in gasification. The pyrolysis module 510preferably includes a dried carbonaceous material inlet that allowsdried carbonaceous material from the drying module 400 to enter thepyrolysis module 510 and a tar gas and charcoal outlet that allows thetar gas and charcoal to exit the pyrolysis module 510, preferably intothe reactor module 550. Similar to the drying module 400, the pyrolysismodule 510 preferably also of a generally cylindrical structure thatincludes an inner jacket and an outer jacket that cooperatively definean annual space in between the inner jacket and the outer jacket. Thepyrolysis module 510 is preferably constructed using similar oridentical materials and methods as described above for the drying module400, but can alternatively be constructed using any other suitablematerial and method.

The annular space surrounding the pyrolysis module 510 preferablydefines the second heat exchanger 520. Exhaust gas from the enginemodule 800 is preferably piped into the second heat exchanger 520 topyrolyze the dry carbonaceous material within the pyrolysis module 510.The temperature of the exhaust gas that enters this annular space can bein the range of 500° C.-700° C., and preferably contains enough heatenergy to heat the dried carbonaceous material to temperatures thatpyrolyze the dried carbonaceous material into tar gas and charcoal.Temperatures necessary to pyrolyze carbonaceous material are generallyabove 220° C. The second heat exchanger 520 preferably includes an inletfluidly connected to the exhaust of the engine 810 of the engine module800, and preferably includes an outlet fluidly connected to the ambientenvironment but alternatively connected to any other suitable fluidreservoir. To minimize the connection length between the pyrolysismodule 510 and the engine exhaust, as well as to minimize thermal lossesfrom the exhaust gas stream, the pyrolysis module 510 is preferablyarranged adjacent the engine exhaust, more preferably in a corneradjacent the engine 810 of the engine module 800 but alternatively inany other suitable location. The exhaust path length is preferablysubstantially less than a side of the skid 110, preferably less than thelength of enclosure, and more preferably less than the width of theenclosure. The fluid connection from the engine 810 to the pyrolysismodule 510 is also preferably insulated to minimize thermal loss fromthe transported exhaust gasses, but can similarly be uninsulated.

The pyrolysis module 510 is preferably located directly above thereactor module 550, and is preferably coupled to the reactor module 550through flange rings and endplates. Furthermore, the pyrolysis module510 is preferably located in a corner of the square footprint. However,any other suitable method of arranging the pyrolysis module 510 can beused. The tar gas and charcoal outlet of the pyrolysis module 510preferably extends into the reactor module 550, allowing tar gas andcharcoal to exit the pyrolysis module 510 and flow directly into thereactor module 550 through gravity. The sealed reactor environment willcause the tar gas to propagate into the reactor module 550, and charwill similarly enter the reactor module via gravity. However, the targas and charcoal can be actively moved into the reactor module 550, forexample with a motor, or can be transported into the reactor module 550using any suitable method. While the tar gas and charcoal outlet of thepyrolysis module 510 can extend into the reactor module 550, the heatfrom the reactor module 550 preferably does not substantially affectheat within the pyrolysis module 510, thus decreasing the thermal loadon the reactor module 550. The depth that the tar gas and charcoaloutlet extends into the reactor is preferably where the temperature ofthe pyrolysis module 510 is substantially higher than that of thereactor module 550 at that particular level, discouraging heat transferfrom the reactor module 550 into the pyrolysis module 510. However, anyother suitable arrangement of the pyrolysis module 510 can be used.

The reactor module 550 of the gasifier 500 functions to combust the targas and to reduce the combusted tar gas with the charcoal. Morespecifically, the tar gas is placed in contact with oxygen at combustiontemperatures to combust, and the combusted tar gas is placed in contactwith the charcoal to reduce into carbon monoxide (CO) and hydrogen (H₂),which can then be used as gaseous fuel. As described above, the tar gasand charcoal enters the reactor module 550 from the tar gas and charcoaloutlet of the pyrolysis module 510. The reactor module 550 preferablyincludes an air path that channels air with a suitable amount of oxygenfrom any suitable air source (e.g., ambient air) to the interior of thereactor module 550, allowing combustion and reduction of the tar gas.The reactor module 550 is preferably of the Imbert reactor type (e.g.,the throat and nozzles), but can alternatively be any other suitablereactor type.

The reactor module 550 is preferably located inside a substantiallycylindrical gas cowling that substantially envelops the reactor module550. The gas cowling also preferably includes sheet metal, flange rings,and end plates that maintain the shape and fasten the gas cowling to thereactor module 550. The gas cowling preferably accommodates a variety ofreactor types. The gas cowling and the reactor module 550 preferablycooperatively define a third heat exchanger 560, an annular spacebetween the reactor module 550 and the gas cowling. The gaseous fueloutlet of the reactor module 550 is preferably fluidly coupled to thegas cowling. The gaseous fuel outlet is preferably located at the bottomof the reactor module 550 (e.g., proximal the skid no or pallet, distalthe pyrolysis module 510), such that the gaseous fuel exits after thereduction reaction from the bottom of the reactor and is directedupwards and around the reactor module 550 by the gas cowling. However,the gaseous fuel outlet can be located at any suitable position. Thishot, gaseous fuel is preferably used to preheat the air used to combustthe tar gas within the reactor module 550, wherein the air path ispreferably located within the annular space between the reactor module550 and the gas cowling (third heat exchanger 560). The air pathpreferably wraps around all or a portion of the reactor module perimeterprior to entering the reactor module interior. The air path inlet ispreferably proximal the reactor module bottom (e.g., end of reactormodule 550 proximal the skid no) and the air path outlet is preferablyproximal the reactor module 550 top (e.g., end of reactor module 550distal the skid no and proximal the pyrolysis module 510), allowing theair path to traverse substantially the entire length of the third heatexchanger 560. However, the air path inlet and outlet can be located inany suitable position. This air path arrangement substantially increasesthe output temperature of the air introduced into the reactor module 550and substantially decreases the output temperature of the gaseous fuel.Additionally, as a result of the heat transfer, the temperature of thereactor module 550 is substantially lower at the top than at the bottom,allowing the pyrolysis module 510 to be inserted into the reactor module550 without substantial heat transfer from the reactor module 550 to thepyrolysis module 510 and facilitating transport of tar gas and charcoalinto the reactor module 550. However, any other arrangement suitablearrangement of the reactor module 550 can be used.

The gas cowling of the third heat exchanger 560 can also include asediment collector located below the reactor module 550 that collectsparticulates that are extracted from the gaseous fuel and/or the ashthat results from the charcoal after the combusted tar gas is reducedwith the charcoal. The sediment collector is preferably removable toallow for the sediments to be disposed of after use. However, any othersuitable arrangement of the sediment collector may be used.

The particulate separator 600 of the power generation system 10functions to extract particulates from the gaseous fuel prior to fuelingress into the first heat exchanger 420. The particulate separator 600can additionally extract heat from the gaseous fuel output prior tousing the heat to dry the carbonaceous material. The particulateseparator 600 is preferably fluidly connected to the outlet of the thirdheat exchanger 560 and to the inlet of the first heat exchanger 420. Theparticulate separator 600 preferably includes a gaseous fuel input thatreceives gaseous fuel from the gaseous fuel outlet of the gas cowlingand a gaseous fuel output that is coupled to the gaseous fuel inlet ofthe first heat exchanger 420. The particulate separator 600 ispreferably operable at high temperatures. The particulate separator 600can be a cyclone module that uses centrifugal force to separateparticulates from the gaseous fuel, but can alternatively include anyother suitable particulate separator. In the process of routing thegaseous fuel through the cyclone module, heat can additionally beradiated out into the ambient environment. To this end, the particulateseparator 600 can additionally include heat-radiating features (forexample, heat fins, a pin matrix, etc.) that facilitate the extractionof heat from the gaseous fuel output during particulate extraction.Furthermore, as heat loss from the generated fuel is inverselyproportional to the fuel flow rate out of the reactor module (e.g., moreheat is lost when fuel flows at lower rates), cyclone operation can beoptimized to adjust the amount of heat extracted by the cyclone (e.g.,by adjusting the fuel flow rate within the cyclone, as determinedempirically or from a chart). The particulate separator 600 ispreferably arranged underneath the first heat exchanger 420 to minimizeconnection length, but can similarly be mounted elsewhere on the gascowling. More preferably, the particulate separator 600 is fluidlyconnected to a portion of the first heat exchanger 420 proximal the skid110. Alternatively, the particulate separator 600 can be thermallyconnected to a water path that receives water from a water source, suchas filter condensate, hopper condensate, or water from a dedicatedexternal water source. The heat extracted by the particulate separator600 preferably heats the water within the water path, vaporizing thewater. The water vapor (steam) can subsequently be fed into the reactormodule to improve gas quality. However, any other suitable arrangementof the particulate separator 600 can be used. The particulate separator600 can be arranged adjacent the hopper 200 to dry the carbonaceousmaterial with the extracted heat. The portion of the particulateseparator 600 proximal the hopper 200 preferably has a larger surfacearea than portions of the particulate separator 600 distal the hopper200, but can alternatively have a similar surface area or any othersuitable surface area. In one variation of the power generation system10, the particulate separator 600 is located below the hopper 200,between the hopper 200 and the skid 110. In another variation of thepower generation system 10, the particulate separator 600 is locatedadjacent the hopper 200, wherein both the hopper 200 and the particulateseparator 600 are mounted to or defined by the skid 10. However, theparticulate separator 600 can be otherwise arranged.

The filtration module 700 of the power generation system 10 functions toextract fine particulates and any remaining tar gas from the gaseousfuel, such that the fuel provided to the carburetor of the engine 810 isclean, engine-grade fuel. The filtration module 700 is preferably apacked bed, made from a cylindrical steel drum that is filled with afiltration media (e.g., fine grain wood chips, activated carbon, etc).Alternatively, the filtration module 700 can be a water scrubber,electrostatic precipitator, ceramic candle, bag house, or any othersuitable filtration system. The filtration module 700 preferablyincludes a gaseous fuel inlet, located substantially near the bottom ofthe filtration module 700 (distal from the drying module 400), and agaseous fuel outlet, located substantially near the top of thefiltration module 700. The gaseous fuel inlet is preferably fluidlyconnected to the first heat exchanger 420, and the gaseous fuel outletis preferably fluidly connected to an engine fuel inlet. The gaseousfuel is preferably piped from the first heat exchanger 420 (the annularspace of the drying module 400), after it has dried the carbonaceousmaterial, into the bottom of the filtration module 700 through thegaseous fuel inlet, wherein the gaseous fuel is filtered as it risesthrough the filtration material, emerging from the gaseous fuel outletas substantially clean gaseous fuel. The filtered fuel is thenpreferably provided to the carburetor of the engine module 800. Thefiltration module 700 is preferably located adjacent to the dryingmodule 400 to minimize the connection length, and is also preferablylocated adjacent the engine fuel inlet and the pyrolysis-reactorassembly. In one variation of the power generation system 10, thefiltration module 700 can be located in a corner adjacent thepyrolysis-reactor assembly corner in the square footprint. In anothervariation of the power generation system 10, the filtration module 700can be located along a longitudinal edge of the enclosure, adjacent thepyrolysis-reactor assembly, more preferably between thepyrolysis-reactor assembly and the hopper 200. However, the filtrationmodule 700 can be located in any suitable position. The power generationsystem 10 preferably includes one filtration module 700, but canalternatively include any suitable number of filtration modules.Multiple filtration modules preferably have substantially similarconfigurations, but can alternatively have different configurations.Multiple filtration modules are preferably fluidly coupled in series,but can alternatively be fluidly coupled in parallel.

The power generation system 10 can require a startup system that pullsgas through the system. To this end, the power generation system 10 canadditionally include an ejector module, blower, fan or other gas drivemechanism coupled to the filtration system. The ejector module ispreferably coupled to the filtration system substantially near thegaseous fuel outlet, but can alternatively be otherwise coupled to thefiltration system, the drying module 400, or any other connection pointdownstream from the reactor module 550. The ejector module output ispreferably coupled to a combustion flare, with variable air mixingsystem to ensure full combustion. The ejector system is preferablycoupled to the top of the filtration system, more preferably to thecenter of the cap, wherein the gas flare preferably extends horizontallyout from the ejector system into the corner of the square footprint, andextends vertically through the corner space provided by the circularhopper of the drying module 400. The ejector system is coupled to an airinput, compressed air is preferably pumped into the ejector systemthrough the air input. When the high velocity of air suddenly expandsinto the wide ejector system, it entrains a large quantity of gas,producing a negative pressure that pulls gas through the filtrationmodule 700 and, subsequently, the rest of the power generation system10. However, the power generation system 10 can additionally include afan at the air inlet of the reactor module that pushes air into thereactor module, a fan or vacuum-generating mechanism (e.g., the engine)that pulls gaseous fuel out of the reactor module, or any other suitablemechanism that induces fluid movement.

The engine module 800 of the power generation system 10 functions toconvert gaseous fuel into electricity. The engine module 800 (genset)preferably includes an internal combustion engine 810 that converts thegaseous fuel into motion, an alternator 850 that converts the motioninto electricity, and a drive mechanism that transfers motion from theengine 810 to the alternator 850. Gaseous fuel is preferably introducedinto the fuel inlet of the engine, more preferably into the carburetorof the engine from the filtration module 700, but can alternately beintroduced from the first heat exchanger 420, the heat exchanger, ordirectly from the third heat exchanger 560/reactor module 550. Asaforementioned, the engine 810 and alternator 850 are preferablyarranged in an in-line configuration, but can alternatively have anysuitable configuration. In comparison to a side-by-sideengine-alternator configuration, the in-line configuration allows for ashorter drive mechanism to be used, and allows for the other componentsof the power generation system 10 to fit within the enclosure footprint.In one variation of the power generation system 10, the engine 810occupies one corner of the enclosure footprint and the alternator 850occupies an adjacent corner. In another variation of the powergeneration system 10, the alternator 850 occupies a corner of theenclosure footprint and the engine 810 is located along the enclosurebody (e.g., along a longitudinal edge but alternatively along a lateraledge). The engine 810 preferably includes a radiator 820 and an exhaust.The radiator 820 is preferably arranged adjacent and/or below the hopper200, but can alternatively be arranged elsewhere. The radiator 820 caninclude a plenum that directs and/or contains heated air radiated fromthe engine. The radiator position is preferably adjustable, but canalternatively be static. The radiator plenum volume and/or direction ispreferably adjustable, but can alternatively be statically fixed. In onevariation of the power generation system 10, the radiator 820 isarranged below a raised end of the hopper base 210. The engine 810 ispreferably oriented with the engine exhaust proximal the pyrolysismodule 510, but can alternatively be oriented with the engine exhaustdistal the pyrolysis module 510. The piping leading from the engineexhaust to the pyrolysis module 510 preferably passes below the hopper200, but can alternatively pass adjacent the hopper 200 or be distalfrom the hopper 200. The alternator 850 is preferably oriented with apower interface (e.g., plugs) proximal an edge of the enclosure 100, butcan alternatively be arranged in any suitable manner. The engine 810 ispreferably an internal combustion engine, and is preferably an inlinecylinder configuration (e.g., 2, 3, 4, 5, or 6 cylinders, etc.) so as tooptimally locate the exhaust manifold output immediately adjacent to thepyrolysis module input. However, any engine configuration is acceptable,with appropriate piping solutions to distribute the hot exhaust to thepyrolysis module. The alternator 850 is preferably a standard 10 kWalternator, but can alternatively be a 20 kW alternator, a 100 kWalternator, or any other suitable alternator that converts motion fromthe engine 810 into electricity. The drive mechanism is preferably adirect drive inline engine-alternator coupled solution, however a beltdrive that couples the crankshaft of the engine to the rotor of thealternator 850 or any other suitable drive mechanism can alternativelybe used.

2. First Specific Example—Configuration for a Standard Shipping Pallet

In a first specific example of the power generation system 10, as shownin FIGS. 1A, 1B, 3A, and 3B, the power generation system 10 isconfigured to fit on a standard shipping pallet (e.g., an ISO standardpallet, North American standard pallet as shown in FIGS. 2A and 2B,European pallet, Australian pallet, etc.). The shipping palletpreferably forms the skid no. The enclosure can additionally includeenclosure walls 120 that are preferably perpendicularly mounted to theskid no to form a fully enclosed system. The enclosure can additionallyinclude a top 130. The pallet preferably has a broad face defining afirst corner adjacent a second corner, a third corner adjacent thesecond corner, and a fourth corner adjacent the first and third corners,wherein the four corners are preferably defined in a common plane. Thepower generation system 10 includes a reactor module 550 located in thefirst corner, a pyrolysis module 510 coaxially arranged above thereactor module 550 (e.g., such that the reactor module 550 is betweenthe pyrolysis module 510 and the pallet), a drying module 400 locatedoffset from and above the pyrolysis module 510 (e.g., such that thepyrolysis module 510 is between the drying module 400 and the pallet),and an engine module 800 (genset) occupying the second and thirdcorners. The power generation system 10 can optionally include anairlock 300 located above the drying module 400 (e.g., the drying module400 is located between the airlock 300 and the pallet) that creates asubstantially fluid impermeable seal with the drying module 400. Thefluid path between the drying module 400, pyrolysis module 510, reactormodule 550, and engine module 800 is preferably substantially fluidlysealed from the ambient environment, sans the air input for the reactormodule 550. The drying module 400 can vertically overlap with some ofthe generator components (e.g., the bottom of the drying module 400overlaps with the top of the pyrolysis module 510), but is preferablyarranged above the rest of the generator components, substantially nearthe center of the pallet footprint. The drying module 400 canadditionally include a material transporter located proximal the palletwithin the drying module 400, wherein the material transporter movescarbonaceous material from the bottom of the drying module 400 into thepyrolysis module 510. The engine module 800 and reactor module 550 arepreferably directly mounted to the pallet, while the pyrolysis module510 is preferably mounted to the reactor module 550 and the dryingmodule 400 is preferably mounted to the pyrolysis module 510. The engine810 preferably occupies the second corner while the alternator 850occupies the third, but the engine module 800 can be otherwise arranged.The power generation system 10 can additionally include a hopper 200above the drying module 400, such that the drying module 400 is betweenthe hopper 200 and the pallet. The hopper 200 preferably has a majordimension (e.g., diameter) substantially equivalent to the width orlength of the pallet. The hopper 200 is preferably an open cylinder witha closed end (wherein the closed end is proximal the pallet), but canalternatively be a cone with the apex proximal the pallet or have anyother suitable configuration. The hopper 200 is preferably collapsibleand comes pre-mounted to the gasifier 500, but can alternatively beshipped as a separate component (in a rigid or collapsed state) or berigid and pre-mounted to the gasifier 500. The hopper 200 is preferablyporous (e.g., made of mesh), but can alternatively be substantiallysolid. The hopper 200 preferably forms an air seal with the rest of thepower generation system 10, but can alternatively be open to the ambientenvironment and include an airlock 300. The airlock 300, when included,is preferably located in the bottom of the hopper 200 (the portion ofthe hopper 200 proximal the pallet), but can alternatively be located inthe drying portion or between the two components. The airlock 300 ispreferably a rotary airlock 300, and is preferably oriented with therotational axis substantially parallel to the broad face of the pallet.The hopper 200 can additionally include a material transporter thatmoves carbonaceous material from the hopper base 210 to the airlock 300.The hopper material transporter preferably traces the profile of thehopper base 210, but can alternatively be at an angle relative to thehopper base 210. The power generation system 10 can additionally includea filtration module 700 located in the fourth corner, wherein thefiltration system is preferably mounted to the pallet. However, thepyrolysis-reactor assembly and filtration module corners can beswitched. The power generation system 10 can additionally include aparticulate separator 600 located between the filtration module 700 andthe alternator 850, near the center of the pallet footprint. Theparticulate separator 600 can include a cyclone module andheat-radiating features, such as fins, but can alternatively be anysuitable particulate separator 600. The particulate separator 6 oo ispreferably located below the drying module 400 (e.g., such that theparticulate separator 600 is located between the drying module 400 andthe pallet). The particulate separator 600 can be directly below thedrying module 400 (e.g., share a common vector normal to the palletbroad face), offset from the drying module 400, located below a portionof the hopper 200, or arranged in any other suitable location. Theparticulate separator 600 is preferably mounted to the reactor module550 (e.g., about the reactor module outlet), but can alternatively bemounted to any suitable generator component. This arrangement preferablyadditionally minimizes the amount and/or length of interconnects byreducing the length of the plumbing runs and arranging the outputexhaust pipe of the engine 810 is preferably arranged proximal to thepyrolysis module inlet. Furthermore, the electrical controls andinstrumentation are preferably arranged on a single conduit 20 (e.g.,wiring conduit including electrical wiring and/or fluid channeling)extending along the center of shipping pallet, in between the reactormodule 550 and the engine module 810. Power and signal connections fromthe gasifier and engine modules are preferably designed to face inward,toward the single distribution conduit 20, for easy connection andminimal wiring. However, the power generation system 10 can include anysuitable number of conduits. The conduit preferably extends through thecenter of the system, wherein the conduit preferably extends parallel toa broad face of the pallet, but can alternatively extend perpendicularto the broad face of the pallet (e.g., vertically). The conduitpreferably additionally includes a user control module 25 (e.g.,arranged along or proximal an edge between the filtration module 700 andthe engine module 800), but can alternatively include any other suitableuser input interface. This arrangement preferably additionally enablessingle-side operation by arranging all the electrical controls andplumbing valves along a single side.

The power generation system 10 preferably includes a first heatexchanger 420 fluidly coupled to the third heat exchanger 560 (and thus,the outlet of the reactor module 550) and thermally coupled to thedrying module 400, wherein the first heat exchanger 420 heats thecarbonaceous material with waste heat from the gaseous fuel. Morepreferably, the inlet of the first heat exchanger 420 is fluidly coupledto the particulate separator 600. The outlet of the first heat exchanger420 is preferably fluidly connected to the filtration module 700 but canalternatively be directly connected to the carburetor of the engine. Thefirst heat exchanger 420 is preferably an annular channel surroundingthe drying module 400, but can be any suitable heat exchanger. The powergeneration system 10 preferably includes a second heat exchanger 520fluidly coupled to the engine exhaust and thermally coupled to thepyrolysis module 510, wherein the second heat exchanger 520 heats thedried carbonaceous material with waste heat from the exhaust gas. Theoutlet of the second heat exchanger 520 is preferably coupled to theambient environment. The second heat exchanger 520 is preferably anannular channel surrounding the pyrolysis module 510, but can be anysuitable heat exchanger. The power generation system 10 preferablyincludes a third heat exchanger 560 fluidly coupled to the outlet of thereactor module 550 and thermally coupled to an air intake for thereactor module 550, wherein the third heat exchanger 560 heats the airused for combustion. More preferably, the third heat exchanger 560receives hot gaseous fuel from the reactor module outlet and egressesgaseous fuel into the particulate separator 600. The third heatexchanger 560 is preferably an annular channel surrounding the reactormodule 550, but can be any suitable heat exchanger.

However, the power generation system components can be otherwisearranged within the pallet footprint.

3. Second Specific Example—Configuration for a Shipping ContainerEnclosure

In a second specific example of the power generation system 10, as shownin FIGS. 4A and 4B, the power generation system 10 is configured to fitwithin a standard intermodal shipping container enclosure. The powergeneration system 10 can be arranged within a 20 foot intermodalcontainer, a 40 foot intermodal container, a 40 foot high cubecontainer, a 45 foot high cube container, or any other suitable shippingcontainer. The shipping container enclosure preferably includes arectangular skid no, four walls extending perpendicularly from the skidno, and a top 130 statically connected to the ends of the four wallsdistal the skid no. The shipping container enclosure preferably has afirst and a second end perpendicular the enclosure longitudinal axis(e.g., the short sides of the shipping enclosure). The enclosure ispreferably divided along its length (longitudinal axis) into a enclosureside occupying the first end and a hopper side occupying the second end,wherein the hopper 200 is located in the hopper side and preferablyoccupies the entire second end of the enclosure. The hopper 200preferably occupies substantially half of the enclosure, but canalternatively occupy more or less of the enclosure. The hopper 200 ispreferably cooperatively defined by an auxiliary wall and three adjacentwalls of the enclosure, and can additionally be defined by the topand/or base. The hopper 200 is preferably an open hopper (e.g., open toambient environment), but can be any suitable hopper. The hopper 200preferably has an angled bottom relative to the skid no, wherein thehopper base 210 preferably has a first end and a second end. The firstend of the hopper base 210 is preferably the short edge of the skid no,and the second end of the hopper is preferably proximal the center ofthe skid no, wherein the distance between the hopper base 210 and theskid no preferably increases with proximity to the center of the skid no(e.g., the second end of the hopper base 210 is further away from theskid no than the first end of the hopper base 210). The hopper base 210is preferably substantially planar, but can alternatively be curved orhave any suitable geometry. The hopper base 210 preferably meets theskid no along the short edge of the second end of the enclosure, but canalternatively meet the skid no along a longitudinal wall. The hopper 200preferably additionally includes a material transporter that functionsto move carbonaceous material from the hopper base 210 toward theenclosure center. The material transporter preferably moves carbonaceousmaterial in a vector substantially parallel to the hopper base 210, butcan alternatively move carbonaceous material in a vector at an angle tothe hopper base 210. The hopper base 210 is preferably porous (e.g.,perforated, formed from a mesh, etc.), but can alternatively be solid.The walls and/or top 130 defining the hopper base 210 are preferablysolid, but can alternatively be porous or articulate relative to theskid no (e.g., have doors). The hopper base 210 and auxiliary wall arepreferably substantially thermally conductive and made of metal, but canalternatively be made of any suitable material.

The remainder of the generator components are preferably located in thecomponent side, wherein the first end includes a first and a secondcorner. The pyrolysis module 510 and reactor module 550 are preferablylocated in the first corner, wherein the pyrolysis module 510 ispreferably coaxially arranged above the reactor module 550 (e.g., suchthat the reactor module 550 is located between the pyrolysis module 510and the skid 110). The reactor module 550 is preferably mounted to theskid 110, while the pyrolysis module 510 is preferably mounted to thereactor module 550 end distal the skid 110 (opposing end). The enginemodule 800 is preferably located in the second corner, arranged with theengine 810, drive mechanism, or alternator longitudinal axis parallel tothe footprint longitudinal axis. The engine module 800 is preferablyarranged with the alternator 850 in the second corner and the enginemodule 800 between the hopper 200 and the alternator 850. The enginemodule 800 is preferably arranged with a control panel and/or powerinterface proximal a longitudinal edge of the enclosure, but canalternatively be arranged with the control panel and/or power interfaceproximal a lateral edge of the enclosure. The engine module 800 can bearranged with the engine radiator proximal the hopper auxiliary wall,wherein the radiator blast can ingress into the hopper and pre-heat andpre-dry the carbonaceous material within the hopper 200. The radiatorblast is preferably directed into the hopper 200, but the hot air fromthe radiator 820 can alternatively be fed to the hopper 200 through apipe or any suitable mechanism. However, the engine module 800 can beotherwise arranged within the enclosure 100. The engine module 800 andthe alternator 850 are preferably mounted directly to the skid 110. Thefiltration modules are preferably located along a longitudinal edgeshared with the pyrolysis/reactor modules 550, between the gasifier 500and the hopper 200. The filtration modules are preferably mounteddirectly to the skid 110. The drying module 400 preferably extends fromthe bottom of the hopper 200 to the top of the pyrolysis module 510along a longitudinal portion of the enclosure. The drying module 400preferably has a first and a second end, wherein the first end of thedrying module 400 is preferably located below the second end of thehopper base 210 (e.g., between the second end of the hopper base 210 andthe skid 110), and the second end of the drying module 400 is preferablyfluidly connected to the pyrolysis module 510 distal the skid no. Thedrying module 400 preferably includes a channel encapsulating a materialtransporter, more preferably includes a channel surrounding a heatedauger. The drying module 400 can be mounted to the hopper base 210,hopper auxiliary wall, or airlock 300 casing at the first end, andmounted to the pyrolysis inlet at the second end. The airlock 300 ispreferably located between the second end of the hopper base 210 and thefirst end of the drying module 400, and preferably forms a substantiallyfluid impermeable seal with the drying module 400. The airlock 300 ispreferably a rotary airlock 300 and oriented with the rotational axissubstantially parallel the skid broad face, but any other type of airlock mechanism can be used. The end material transporter of the hopper200 preferably extends over the airlock-hopper junction, such thatcarbonaceous material is dropped into the airlock 300. The airlock 300is preferably mounted to the hopper auxiliary wall and hopper base 210.The particulate separator 600 can be located proximal the center of theenclosure 100. Alternatively, the particulate separator 600 can belocated between the engine 810 and the auxiliary wall of the hopper 200,wherein the heat exchanger preferably heats and/or dries thecarbonaceous material within the hopper 200 with waste heat extractedfrom the gaseous fuel. The outlet of the particulate separator 600, morepreferably the entirety of the particulate separator 600, is preferablylocated below the inlet of the first heat exchanger 420 (e.g., betweenthe first heat exchanger inlet and the skid 110), but can alternativelybe located elsewhere. The particulate separator 600 is preferablymounted to the outlet of the third heat exchanger 560, but canalternatively be mounted to any suitable component of the powergeneration system 10. The enclosure 100 preferably has doors along thewalls defining the enclosure first end, such that the generatorcomponents can be accessed.

The power generation system 10 preferably includes a first heatexchanger 420 fluidly coupled to the third heat exchanger 560 (and thus,the outlet of the reactor module 550) and thermally coupled to thedrying module 400, wherein the first heat exchanger 420 heats thecarbonaceous material with waste heat from the gaseous fuel. Morepreferably, the inlet of the first heat exchanger 420 is fluidly coupledto the particulate separator 600. The outlet of the first heat exchanger420 is preferably fluidly connected to the filtration module 700 but canalternatively be directly connected to the carburetor of the engine. Thefirst heat exchanger 420 is preferably an annular channel surroundingthe drying module 400 (e.g., extending along the longitudinal axis ofthe drying module 400), but can be any suitable heat exchanger. Theinlet of the first heat exchanger 420 is preferably proximal to thefirst end of the drying module 400 and the outlet of the first heatexchanger 420 proximal the second end of the drying module 400.Alternatively, the outlet of the first heat exchanger 420 is proximal tothe first end of the drying module 400 and the inlet of the first heatexchanger 420 is proximal the second end of the drying module 400.Alternatively, the first heat exchanger 420 includes two fluid channelswith opposing flow directions that are fluidly connected at one end,wherein the inlet and outlet of the first heat exchanger 420 can belocated proximal the pyrolysis module 510 or the hopper 200. The powergeneration system 10 preferably includes a second heat exchanger 520fluidly coupled to the engine exhaust and thermally coupled to thepyrolysis module 510, wherein the second heat exchanger 520 heats thedried carbonaceous material with waste heat from the exhaust gas. Theoutlet of the second heat exchanger 520 is preferably coupled to theambient environment. The second heat exchanger 520 is preferably anannular channel surrounding the pyrolysis module 510, but can be anysuitable heat exchanger. The power generation system 10 preferablyincludes a third heat exchanger 560 fluidly coupled to the outlet of thereactor module 550 and thermally coupled to an air intake for thereactor module 550, wherein the third heat exchanger 560 heats the airused for combustion. More preferably, the third heat exchanger 560receives hot gaseous fuel from the reactor module outlet and egressesgaseous fuel into the particulate separator 600. The third heatexchanger 560 is preferably an annular channel surrounding the reactormodule 550, but can be any suitable heat exchanger.

However, the generator components can be otherwise arranged in astandardized shipping container enclosure. Alternatively, any suitablearrangement of the modules can be used.

As a person skilled in the art will recognize from the previous detaileddescription and from the figures and claims, modifications and changescan be made to the preferred embodiments of the invention withoutdeparting from the scope of this invention defined in the followingclaims.

We claim:
 1. A gasification based power generation system that convertscarbonaceous material into electrical power, comprising: an open-airhopper; an airlock connected to an outlet of the hopper; a drying moduleconnected to the airlock, the airlock configured to form a substantiallyfluid impermeable seal with the drying module; a gasifier comprising: apyrolysis module and a reactor module, the pyrolysis module connected tothe drying module and to the reactor module; an engine; and a heatexchange module comprising: a first heat exchanger fluidly connected toan outlet of the reactor module and thermally connected to the dryingmodule; a second heat exchanger fluidly connected to an outlet of theengine and thermally connected to the pyrolysis module; and a third heatexchanger fluidly connected between the outlet of the reactor module andthe first heat exchanger, the third heat exchanger thermally connectedto an air inlet of the reactor module.